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82' xj750 maxim repairs.

Discussion in 'XJ Technical Chat' started by Bix, Jul 11, 2019.

  1. Bix

    Bix Member

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    Nice. Yea that's definitely the plan . Started catching up on your thread , good work man!
     
  2. Bix

    Bix Member

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    So ive been enjoying the bike but the rainy winter is setting in and with the cost of insurance and my wanting of wrenching i have benched her for the winter to get some much needed things done. I figured id start with the carbs since i know my last go around of "cleaning" them didnt include throttle shaft seals, fuel rail interconnnect seals, mixture screws ( and springs ) ect.. I spent a few days reading the chruch of clean and figured id get started the other day. I cleaned off a nice perfectly flat workspace ( my glass drafting table ) and got to work, taking lots of photos, i know the church of clean recommends 100 and i think im going to have just a little more by the time these are done being dissaembled. Ive gotten as far as to breaking the rack, i stopped to do more reading on the next sections rather than continuing like my brain is telling me too. Now is where things seem to get very precise and important compared to the first steps. with all the throttle blades, screws, seals and spring placements.

    My rebuild kit came with 6 new o rings for the fuel rail interconnect tubes but they dont fit perfectly so im going to order some from chacal. Well see what else doesnt seem perfect and all that will be ordered as well.


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    The new o rings provided.. maybe they are for something else but there is 6 of them so i dont see what else theyd be for.. i definitely dont like the look of that seal so like i said i will be ordering some other ones.

    IMG_20191006_084559.jpg


    A question i have going into the next section is

    - Ive read about filing the back of the throttle shaft screws, mine seem to have a bevel to them already and i can tell these have been broken before by how easily the rack screws came out ( other threads say they should be very difficult to remove ). The throttle shaft screws seem to be almost flush with the shaft already.. id hate to have the file hit the shaft at all with how little protrusion there is currently but will do whats necessary.

    Here are some photos even though they might be hard to see.


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    I am going to be going alot slower than i want to with the disassembly of the rest, its intimidating, not from a skill level but from the amount of importance stressed in the threads about doing this right. Maybe ill even hit 200 photos by the time im done.

    Thats all for now, Im going to keep reading and reading and reading and maybe get a bit further today. Good thing about it having the plates taken off of it is there is NO rush to get this done, i got months and months to tackle my list of objectives.

    I keep reading about doing it right or not doing it and im gonna do my best to tackle this properly for the second time and avoid the 3rd and 4th haha
     

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  3. Bix

    Bix Member

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    another question is what grit is appropriate for polishing the slide bore in the carb body and the slides themselves ( i have some varnishing on the bottom of them )
     
  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    do not polish slides with any sandpaper, it will ruin them. clean with cleaner and soft rag.


    only Mikuni carbs need the screw filed down the screws are peened
     
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  5. Bix

    Bix Member

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    I got the throttle blades out. Marking each ones orientation . I marked them with an arrow pointing down towards the bowl. After taking about 50 photos I started to take out the shafts along with the accompanying springs and seals. Laying them above the carbs in the exact orientation they came out. The shaft seals seem good as to not be originals but who knows. Some have some small cracks on the inside flange type part of the seal so I'm just going to replace them all anyway. I've come this far, to not replace a questionable part would be ridiculous naive. Behind where the throttle blades attach to the shaft is some tarnishing. Will clean up with cleaner and a soft cloth as to not score anything. Is this a sign of anything I should prbe besidesconcearned about beside prolonged exposure to fuel? IMG_20191006_113500.jpg IMG_20191006_114609.jpg IMG_20191006_114410.jpg IMG_20191006_114400.jpg IMG_20191006_114357.jpg IMG_20191006_114355.jpg IMG_20191006_114351.jpg IMG_20191006_114204.jpg IMG_20191006_114205.jpg
     
  6. Bix

    Bix Member

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    Also the 6 plastic washers That accompany the outside of the throttle shafts.. should those be replaced with new ones while I'm here even though they appear fine, as I'm assuming they act as a dust guard for the throttle shaft seal.
     
  7. Timbox

    Timbox Well-Known Member

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    Nice share, great pics...even in focus! Even with the correct "O" rings you will have to make sure the carbs side of those fuel tubs are supper clean. I have had some so bad that I have had to polish them with my dremel and a polishing head. Using a little oil like MMO on the rings and carb parts might help too. Great job on the tear down and sharing the pics and how you are doing with the project. Keep up the great work!
     
  8. Bix

    Bix Member

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    Thanks! ill probably be worried until the motor is tuned to the carbs afterwards, the valve shims have been checked/replaced and i hear it run properly. Trying to use that as a good thing though!

    Yea i took some photos of the inside portion of the carb where the tubes go in.. not clean.. neither are the insides of the tubes. Going to find a tool to clean both good!

    what do you mean by MMO? and thanks for the tip!
     
    Last edited: Oct 6, 2019
  9. XJ550H

    XJ550H Well-Known Member Premium Member

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    should be more than 6 spacers 7 needed. do not always needed to be replaced
     
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  10. Bix

    Bix Member

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    You're right. I actually have 8... One on either side of the throttle shaft bracket or on the ends the circlip goes onto ( carb 1 and 4 ). Okay they all seem straight and without damage.
     
    Last edited: Oct 6, 2019
  11. Bix

    Bix Member

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    i sprayed the throttle blades with some cleaner and tried to get as much of the tarnish off that i could. whats left isnt able to be felt with a finger so im assuming it should be okay, i may soak them if needed. I havent taken out the enrichment circuit plungers and springs yet, they all slide smooth and have the same tension to them, should i just take them out while im here? i know the answer is probably yes but why not ask haha?

    I then just cleaned the carb bodys and the fuel interconnect passages. ive inquired about a quote to get the throttle shaft seals and fuel rail o rings as well.

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  12. XJ550H

    XJ550H Well-Known Member Premium Member

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    "On the HSC32, carbs #1, #2, and #4 use 2 shims per carb, and the #3 carb uses only 1 shim. Thus, on HSC32 model carbs, there are a total of 7 shims used per entire carb rack."
    xj4ever catalog
     
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  13. Bix

    Bix Member

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  14. XJ550H

    XJ550H Well-Known Member Premium Member

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    I havent taken out the enrichment circuit plungers and springs yet, they all slide smooth and have the same tension to them, should i just take them out while im here? i know the answer is probably yes but why not ask haha?

    you need to remove them to inspect springs for rust and that the seats for them are clean
     
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  15. Bix

    Bix Member

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    And yea you're right, again haha. Was confusing the locking washer on number 3 as one. Too much carb cleaner fumes today I think.. classic. Good thing I stopped for the day.
     
  16. Bix

    Bix Member

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    Enrichment circuit is taken out now. Besides some crud on the parts that see the day light , they seem to be in good shape. The seats inside the carb body seem good too, theyll get a quick cleaning anyway of course, but im pleased to see i dont need more parts to order !

    Im pretty much on hold now until i make the order of parts and they arrive for re install. I want to start some other tasks but im trying to complete only one thing at a time so it all stays fresh, and the improvements i make on the bike this winter dont get lost in a bunch of half done mini projects, been there before...

    So far i have new throttle shaft seals, hex head button screws (to replace the phillips heads in the throttle shaft/ butterfly ), Fuel supply o rings, and idle mixture screw orings on the list and i think thats all i need.

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  17. Bix

    Bix Member

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    Im not sure why all my photos from dropbox seem to go sideways on this site... not this one atleast.



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  18. Bix

    Bix Member

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    Even though i dont see much grime on them should i still soak them in parts cleaner? or am i fine just cleaning them by hand like i am, and then blowing them out with a compressor?
     
  19. Bix

    Bix Member

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    Also got the mixture screws out. Carb 3-4 has some cruddy screws, springs, and washers. Good thing the rebuild kit came with 4 new mixture screws and hardware.

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  20. Bix

    Bix Member

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    Does the spring act like a lock in ensuring this mixture screw doesn't back off , or what purpose does it have?
     

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